training presentation of sarena industries

1. TRAINING PRESENTATION
BY
ZUHAIR BIN JAWAID
MTO

2. PRE-TREATMENT

3. SINGEING
•Singeing improves the end use and wearing
properties of textiles.
•The burning-off of protruding fibers results in a
clean surface.
•The projecting fiber and the dyed fabrics appear
brighter.

4. DESIZING
Parameters:
• Temperature = 60°C
• pH = 6-7
• Concentration of the chemicals

5. RECIPE
Sr.No Chemical Concentration For Cotton (g/L) Concentration For PC (g/L)
1 Hygen SPL 2 2
2 Chromo Quest 2 2
3 Ecozyme 1 1

6. Sr.
No.
Chemical
Commercial
Name
Chemistry Funtion
1 Wetting Agent Hygen SPL
Sulphonates+organic
compounds+surfactants
Increase Wettability
2
Sequestering
Agent
Chroma Quest Organic Complex
Sequester against
metal ions
3 Enzyme ECOZYME Alpha-Amylase Desizer
4 Oxalic Acid C2H2O4 Oxalic Acid
To remove rust from
fabric

7. SCOURING
The action of alkaline scouring agent is to:
• saponify any residual oils
• to neutralize carboxylic acids
• to solubilize any sizing materials
• to cause dispersion of naturally occurring impurities in natural
fibers.

8. BLEACHING
• The object of bleaching is to produce white fabrics by destroying
the coloring matter.
• Hydrogen peroxide liberates per hydroxyl ion (HO2-) in aqueous
medium.
• HO2
- at higher pH (above 10.8) the liberation of ion is so rapid.
• an optimum pH for bleaching lies between 10.5 to 10.8.

9. Sr. No Chemical Commercial Name Chemistry Function
1 H2O2 H2O2 H2O2 Bleaching Action
2 NaOH NaOH NaOH Scouring + pH
3 Stabilizer Chroma Bleach Non- silicate peroxide
Decomposition of
Peroxide
4 Sequestering Agent Chroma Quest Organic Complex
Sequester against
metal ions
5 Wetting Agent Hygen SPL
Sulphonates+organic
compounds+surfactants
Increase Wettability

10. MERCERIZATION
• Application of caustic soda solution
• A dwell period, to permit diffusion of alkali into the fiber.
• Finally, washing-off of the traces of alkali from the treated fibers.

11. DYEING

12. DYEING
For Cotton:
Reactive Dye
Vat Dye
Sulphur Dye
FOR PC/CVC:
DISPERSE/VAT
DISPERSE/REACTIVE
PIGMENT

13. RECIPE(REACTIVE)
Sr. No.
Chemical Commercial Name Chemistry Function
1 Urea Urea Urea To retain moisture
3 Soda Ash Soda Ash Na2CO3 For dye fixation
4
Anti-migrating
agent
Chroma dye - To avoid migration
5
Anti-reducing
agent
Ultraprint RG3x -
To avoid hydrolysis of dye
molecule
6 Wetting agent Invadine PBN
Ethoxylated fatty alcohol &
araliphatic ether alcohol
For penetration

14. RECIPE(VAT DYE)
Sr.
No.
Chemical Commercial Name Chemistry Function Concentration
4
Dispersing
Agent
Perigen DLS
Modified linin
sulphonate
For dispersion of dye 5 g/l
5
Anti-migrating
Agent
Chroma dye - To avoid migration 15 g/l
6 Acetic acid Acetic acid CH3COOH To neutralize the fabric 2 g/l

15. RECIPE(VAT DEVELOPMENT)
Sr.
No.
Chemical Commercial Name Chemistry Function
1
Sodium
Hydrosulphite
Sodium
Hydrosulphite
Na2S2O4 For reduction of dye
2 Caustic Soda Caustic Soda NaOH
To maintain pH for
reduction
3 Hydrogen Peroxide Hydrogen Peroxide H2O2 For oxidation of dye
4 Acetic acid Acetic acid CH3COOH
To maintain pH for
oxidation

16. RECIPE(DISPERSE/VAT)
Sr. No.
Chemical Commercial Name Chemistry Function
4 Dispersing Agent Perigen DLS Modified linin sulphonate For dispersion of dye
5 Anti-foaming Agent Alviron VKS
Combination of esters, alcohol
and hydrocarbons
To avoid foaming
6 Acetic acid Acetic acid CH3COOH For acidic pH
7
Anti-migrating
agent
Chroma dye - To avoid migration

17. RECIPE(DISPERSE/VAT CHEMICAL PAD)
Sr.
No.
Chemical Commercial Name Chemistry Function
1
Sodium
Hydrosulphite
Sodium
Hydrosulphite
Na2S2O4
For reduction of vat
dye
2 Caustic Soda Caustic Soda NaOH
To maintain pH for
reduction
3 Hydrogen Peroxide Hydrogen Peroxide H2O2 For oxidation of dye
4 Acetic acid Acetic acid CH3COOH
To maintain pH for
oxidation

18. RECIPE(DISPERSE/REACTIVE)
Sr. No.
Chemical Commercial Name Chemistry Function
1 Dispersing Agent Perigen DLS Modified linin sulphonate For dispersion of dye
2 Acetic acid Acetic acid CH3COOH For acidic pH
3
Anti-migrating
agent
Chroma dye - To avoid migration
4 Anti-reducing Agent Ultraprint RG3X - To avoid reduction of dyes

19. RECIPE(DISPERSE/REACTIVE CHEMICAL PAD)
Sr.
No.
Chemical Commercial Name Chemistry Function
1 Sodium Chloride Salt NaCl To avoid bleeding
2 Caustic Soda Caustic Soda NaOH For fixation of dye
3 Soda Ash Soda Ash Na2CO3 For fixation of dye

20. RECIPE(PIGMENT)
Sr. No.
Chemical Commercial Name Chemistry Function
1 Anti-migrating agent Migrosol Mi - To avoid migration
2 Binder Binder Tow Aqueous acrylate dispersion For fixation of pigment
3 Anti-masking Agent Padicoll Dye Ethylene oxide adduct
To avoid deposition of binder on
padder
4 Liquor Ammonia Liquor Ammonia NH4OH
To give basic pH to avoid pre-cross
linkage of binder
5 Softener Cepreton Fatty amide To give softness to fabric
6 Anti-foaming Agent Alviron VKS
Combination of esters, alcohol and
hydrocarbons
To avoid foaming

21. PRINTING

22. DESIGN STUDIO
Creation
Separation

23. ENGRAVING
• Rotary Screen Engraving
• Flat Screen Engraving

24. PRINTING
For Cotton:
Reactive Print
pigment
FOR PC/CVC:
DISPERSE/VAT PRINTING
PIGMENT PRINTING

25. MACHINES
• Flat screen printing machine
• Rotary screen printing machine

26. FLAT SCREEN
• Reggiani
• 8 colors capacity
• Rubber blades
• 1 screen for 1 color
• Semi continuous

27. ROTARY SCREEN
• Stork:
9 colors
Metal Blade squeegee
Impression rollers
continuous
• REGGIANI:
8 COLORS
ROD SQUEEGEE

28. REACTIVE PRINTING
• First stock paste was made by ½ tank of water and 4-5% of
NaHCO3.
• Then stirred for some time after that 2-3% of Na Alginate was
added and then again stir for 20-25 minutes.
• Then add 10-15% of urea (20% for viscose) then stir for 5-7
minutes.
• Then anti-reducing agent was added and again stirred for 5-7
minutes.
• Now the stock paste was ready.

29. FINISHING

30. FINISHING
Mechanical Finishing:
• Sanforizing
• Peaching
• Pentek softening
CHEMICAL FINISHING:
• RESIN FINISH
• WATER REPELLENT
• FR
• SOFTENERS
• ANTI-PILLING

31. FINAL INSPECTION & FOLDING

32. FINAL INSPECTION & FOLDING
• The system used for inspection was 4-point system.
• Maximum 4 penalty points can be assigned per linear meter.
• Standard by customer for acceptance criteria of passing criteria
• otherwise it will be considered as ‘B’ Grade.

33. FAULTS
• Shade variation
• Elephant Skin
• Crease
• Design Out
• Color Bleeding
• Miss Print
• Color Stain
• COLOR STREAKS
• COLOR RAGGAR
• BLACK RAGGAR
• WHITE SPOT
• STEAMER MARK
• FOLD MARK
• YELLOW STAIN.

34. QUALITY CONTROL LAB

35. QUALITY ASSURANCE LAB
• Width: ASTM D-3774
• Fabric construction: ASTM D-
3775
• Blend: AATCC 20A
• Shrinkage:ISO-6330
• Skewness: AATCC 179
• Tear strength: ASTM D-1424.
• Tensile strength: ASTM D-
5034
• Wrinkle recovery: AATCC 128
• Ph: ISO 3071
• ELONGATION:ISO-14704-1
• FORMALDEHYDE: ISO EN 14184-1
• CREASE RETENTION: AATCC 88
• SOIL RELEASE: AATCC 130
• WATER REPELLENCY: AATCC 193
• OIL REPELLENCY: AATCC 118
• FIRE RETARDANCY: ISO 15025
• CHEMICAL PROTECTION: EN ISO
13034
• PERSPIRATION FASTNESS: ISO 105
E04
• WASH FASTNESS: ISO 105 CO6

36. DYEING LAB
• Lab Dips
• Strike offs
• Shade matching
• Keeping records of dips

37. PRODUCTION PLANNING AND CONTROL
• Main aim of ppc is to keep processing smooth
• Processing advice from marketing
• Advance planning of production is done
• Processing is prioritize according to delievery date
• Machine planning
• Lab dips , strike offs
• Reports ( workin progress, machine progress)

38. • Balance of issuance
. Input=output
• fabric issuance according to capacity of machines
• Costing

39. GREY INSPECTION

40. GREIGE STORE
• Receiving
. Gatepass, purchase order
• Stock
Valuated stock = sarena (green card)
Non valuated stock = Commercial(white card)
• Issuance
. Issuance according to ppc production plan

41. FOUR POINT INSPECTION SYSTEM
Length of defect Points allotted
Up to 3 inches 1
Over 3 up to 6 inches 2
Over 6 up to 9 inches 3
Over 9 inches 4
Openings and holes
1 inch or less 2
Over 1 inch 4

42. FAULTS
• Double end
• Loose end
• Hard size
• Size stains
• Sizing balls
• Miss pick
• Double pick
• Hanging thread
• Wrong drawing
• BROKEN END
• FLUFF
• TEMPLE MARKS
• KNOTS
• SLUB
• HOLES
• CUT
• TEAR